Method of making winding loops for bar wound armatures



METHOD OF MAKING WINDING LOOPS FOR BAR WOUND ARMATURES v. (5. APPLE Filed Feb. 5, 1950 2 Sheets-Sheet l ZI/I:

1N VENTOR WVW Dec. 8, 1931. v APPLE 1,834,926

METHOD OF MAKING WINDING LOOPS FOR BAR WOUND ARMATURES Filed Feb. 5, 1930 2 Sheets-Sheet 2 INVENTOR Patented Dec. 8, 1931 PATENT OFFICE VINGENT' G. APPLE, OF DAYTON, OHIO 'METH-OD 0F MAwKING WINDING LOOPS FOB BAR WQJUN-D ARMATURES This invention is shown, though not claimed, in my copending application Serial- Number 319,640, lilcd November 15th, 1928, and-relates to single turn bar wound arma- -5 tures and is particularly adaptable to endwise entry of the winding.

One of the objects of my invention is to provide an integral winding unit comp-rising a loop having its open ends adapted to 1i) compose commutator segments.

Another object of my invention is to provide an armature having a maximum of its core; and winding material efl'ectively employed, by producing 'coreapertures of the most eilect-ive contour and forming commercially procurable' material without waste into-conductors that will conform to thecontour of the core apertures selected and be readily assembled therein.

Further objects will be apparent to-those skilled in theart upon consideration of the description and drawings wherein Fig. 1 is a plan'view of a loop bent from roundwire representing a turn of the winding.

Fig. 2 is anend view of Fig. 1.

Fig. 3 represents a die by means'ofwhieh the roundcrosssection of the loop is changed to different cross sections at parts of its length 1 V 1 shows the loop afterit' has been pressed-in the die, Fig 3.

i Fig; 5 isa cross section taken on'line 55 of-Fig. at. i

G'is'a cross section taken on line 6'6 of Fig. 4.. I

Fig. 7 is a cross section taken on line 77 of Fig. 1. V p v Fig. 8 shows how a legot the outer layer may be pairedwith a leg of the inner layer of the winding to form a composite wedge shaped section. j

Fig. 9 isv a CIOSSfGCtiOD taken-online' 99 of Fig. 8.

-Fig. 10 is across section take-n on the line 10 10 otFig. 8'. i Fig.- 11 showsatype of core aperture to which loops, ig; 4, are. particularly applicable;

Application filed February 5, 1930. Serial No. 426,177.

Fig. 12 shows a core with its apertures completely filled with loops Fig. l. v

Fig. 13 shows how the terminals of the entire inner layer of the winding may bed'isplaced radially inward.

F 14 shows one pair of terminals after the terminal ofthe inner layer has been displaced radially inward. I

Fi 15 shows how the terminals are circum erentially displaced, the outer layer; in one direction and the inner layer in the'other direction.

Fig. 16 show an armature after the outer layer of terminals has been displacedradi ally inward and the terminals brought to gether tocompose a commutator;

Similar numerals refer tosimilar parts throughout the several views.

Fig. 1' is a plan view and Fig. 2 an end view illustrating steps in the method of making a loop, wherein a predetermined length of round Wire has been cut off and bent to loop formation as at 20, having extending therefrom a leg 21 which will later become part of the inner layer of the winding and which may therefore be called" an inner con ductor leg and a leg'22 which will later he'- come apart of. the outer layer of the winding and' which may'tlierefore' be called an" outer conductor leg. slightly out of alignment with theremaining portions of the logs, the amount and" direction-of the-bendsbeing such that those ends will be equally distant from the armature axis and will extend parallel therewith.

' After the loop has-been formed, as in Figs. land 2, itis placed ina dieas inFig; 3. The die here shown is for illustrative purposes only and consists of an upper port'ion25 and a lower portion 26'between which theloo'p is pressed to change the crosssectional contour of parts of itslength, andto bring the loop to the form shown in' Fig. 4, wherein the cross sectiol of the leg 21'l1as-becn changed from roundto the form shown in Fig.5, the other leg 22'havi'ngbeenleft'round asin Fig. 6 and the ofi'set terminals 23 and 24 flattened to theshape asshown'in Fig; 7: By having ofisetthe" terminals, as'at' 23 and 24 Fig. 1, the flattened ends 27 and 28 will 'o'ccupy'p'osi tions of equal distance from the core axis while the parts 21 and 22 will be at different distances therefrom, so that When a leg 21 of one loop is paired with a leg 22 of another loop they will arrange themselves substantially as shown in Fig. 8 wherein legs 21 and 22, relatively to their final position in the core are radially one abovethe otheras in Fig. 9, and the flattened ends 27 and 28 are circumferentially adjacent as in Fig. 10.

This arrangement of pairs'of' the contour shown is particularlyadaptable to endwise entry into core apertures of the type'shown at 31, Fig. 11 and an entire winding composed of loops so constructed may be'assembled with their ends slightly entered into theapertures of a core and simultaneouslypushed into place,.as more clearly described in my Patent.1,555,931. r

The core apertures maybe lined with insu:

lators as at 32, and apartitioning rib ais at 33 I may be placedbetween the two legs of a pair, or the insulation may be applied to the legs ofthe loop before entry into-a .core.

hatter the entire winding has'been assembled and pushed into place in a core 34, as shown in F ig.l2, provision must be made to rearrange the pairs of terminal ends 1 211-28 Tinto other pairs, and to do this the entire set of jinnerlayer terminals27 is radially" displaced. in a nanner similar to the several terminals'shown in theend view Fig. 13. The displacing of these terminals may be accomplished singly with a plunger as at 35, or,a tool may be constructed having a plurality'of plunger-s to displace all terminals of the layer simultaneously. J

. part section F 14 shows the pair of terminals of an aperture after the inner layerterminal has been radially displaced, and while I here showthe inner layer of terminals :as .having been displaced radially inwardleaving the outer layer in gnormal position, it isobvious that as an alternative the outer layer maybe displaced radially,

outward leaving: the-inner layer in normal position or both layers may be displaced, the

one inwardly and the other outwardly, the 7 object being to separate thev circumferentially adjacent flattened ends into cylindrical lay-' ersin order that the ends, :of; one layer will not-interferewiththeends of the other layer when circumferential displacement of the otherlayer is taking place.

ends ofone layer relative to'the ends of the F/Vhenthe entire set of-inner layer terminals has beenradially displaced in a manner indicated in F igs. 13 and 14:, all of the terminals aresimultaneously moved, the outer layer circumferentially in one direction and the; mnerglayer circumferentially in the otherd rection, an amount corresponding to the front pitch ,of the winding leaving the term nal ends 27 and 28 extending parallel to the coreaxis.

An armature with the Winding so bent is shown in Fig. 15, several outer layer bars being broken away forclearness and while I show the layers as being bent equal amounts, they may be bent the one layer more than the other or, both layers may becbent different ployed in Fig. 13 to displace the inner layer,

and thusthe terminals 27 and 28 are again brought circumferentially adjacent in rearrangedpairs as shown in- Fig. 16, where both outer layer terminals 28 and inner layer terminals27 are circumferentially adjacent in cylindrical formation of relatively'small diameter. The terminals however, may be arranged in a circle of larger diameter by leaving more space between pairs,or by adding a metal pad to each pair;

When the steps of the method of making an armature have progressed to the stage shown in Fig. 16 some form of binding means must be applied to hold the parts of the com? mutator together, the terminals comprising pairs in electrical contact, and the whole se'- curely held against centrifugal force, and since in my co-pending application Serial No. 234,158 I describe a process suitable for binding these ends the same will not be herein repeated, as the methods therein disclosed may be applied equally well to the present invention. A notch as at 35, or, other projection which the bindingmeans may engage, may be cut in the terminal ends either separately or after they are assembled as shown, or suitable projectionsmay'be formed on the terminal ends in thedie Fig. 3. A, single turn bar winding isusually arrangedintwo-concentric layers so that the portions of the bars which project beyond the ends of 'thefcore mayextend, the; one

layer helically' right handed and .the other layer helically left'handed, andby such an arrangement a bar of one layer'mayjoin a Widely separated bar of another layer through their helically projecting ends without interference or'contact with the helical ends of otherbars of the winding. It is therefore obvious that the conductors of such a winding need be arranged in twoconcentric layers only at such, portions of'their length as are helically disposed, and that all other portions of the winding may be comapparent that in the process of making the loop these aperture portions may be brought to positions radially equal to each as are the parts 23 and 24 Fig. 1, after which the die Fig. 3 may flatten these aperture portions to the cross sectional contour of the terminal ends Fig. 7. Such a winding would coniprise hclical portions in two concentric layers and aperture and terminal end portions composed of parts circumferentially adjacent in. a single cylindrical layer. As it is sometimes considered advantageous to have wide thin conductors circumferentially adjacent in a core aperture rather than thicker narrower conductors radially one above the other, the loops may be so made when the advantages to be gained justify.

While I have shown and described my method of making an improved winding as consisting of a number of steps in a given sequence, it is obvious that the steps need not necessarily be taken in the exact sequence indicated, but may be reversed or rearranged, or steps described as separately taken may be combined if so desired, and while I have shown round as a preferred form of Wire for making loops comprising a winding, 1 do not wish to limit myself to the use of round wire, as wire of a modified form may be used, one feature of the invention consisting in providing a loop by using wire of uniform cross sectional contour throughout its length to form the conductors, and altering the cross sectional contour at parts of the length of the conductors, in such manner that those portions of the conductors which are necessarily arranged one radially above the other have cross sections adapted to that purpose while other portions which preferably occupy circumferentially adjacentposit-ions are also suitably shaped, without altering the current carrying capacity at any point in the loop, yet maintaining such cross sectional contours at the altered portions that the composite contour of a pair of conductor legs throughout the length of a pair may substantially conform to the shape of a winding aperture so as to be endwise enterable therethrough. 7

Having described my invention, I claim- 1. A method of making an integral winding loop for an armature which consists of providing wire of substantially half the cross sectional area of a winding aperture and of a cross sectional contour to substantially fill the wider half of said aperture, bending loops from said wire, reshaping one leg of the loop to conform to the narrower half of said aperture, and reshaping the open ends of the loop to substantially conform to the entire depth but only half the Width of said aperture.

2. A method of making a winding loop for a bar armature, having elongated winding apertures wider at one end than the other, from a- Wire of such cross sectional area and contour throughout its length as will substantially conform to the wider end of one of said apertures, which consists of bending the wire in the form of a loop with two equal widely spaced apart legs, the one leg being adapted to take a position in the armature farther from the axis than the other leg, offsetting the open ends of the loop until both ends are adapted to take positions equidistant from the said axis, then placing the loop between surfaces of a die comprising a series of different planes and pressing one leg to a shape substantially conforming to the narrower half of one of said apertures and the open ends to a shape substantially half the thickness and double the width as the original bar.

3. A method of making a winding loop for a two layer bar armature, having wedge shaped winding apertures, from wire which substantially conforms to the wider end of one of said apertures, which consists of bending the wire in the form of a loop, with two equal widely spaced apart logs, the one leg being adapted to take a position in the outer layer of the winding and the other leg being adapted to take a position in the inner layer of the winding, offsetting the open ends of the loop to. positions which will be equidistant from the axis when in the armature, then placing the loop between surfaces of a die comprising a series of radial planes and pressing the one leg thinner and wider and to a wedge shape substantially conforming to the narrower half of one of said apertures, and pressing the ends to a wedge shaped contour of substantially half the thickness and double the width of the original bar.

In testimony whereof I atlix my signature.

VINCENT G. APPLE.

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